CASTING INNOVATIONS
Remote-Controlled Demolition Machines Improve Operator Safety Within metalcasting facilities,
“It’s evident how the machines
weekly cleaning tasks such as refrac- tory removal can require operators to hold up 30-lb. chipping guns and 40- lb. rivet busters to remove the caked-on material inside and around the ladles. Such tasks can take hours to complete, which may lead to muscle strain and an increased risk of injuries. Chipping guns and rivet busters are
effective methods to remove refrac- tory, but they produce heavy vibrations that transfer directly to the operator. Prolonged use can lead to nerve dam- age, hand-arm vibration syndrome and other chronic conditions. Waupaca Foundry, Waupaca, Wis-
consin, found a solution that combats the heat and danger with remote-con- trolled demolition machines. Manu- factured by Brokk, a Swedish company with U.S. headquarters outside Seattle, these machines provide the needed hard-hitting power, precision and versatility to remove the thick refractory material. Waupaca has been using the remote-controlled machines for more than a decade.
reduce physical stress and injuries, and provide our team the most efficient and safe means for refractory removal applications,” said Steve Heger, assis- tant melt manager, Waupaca Foundry. “And they allow us to offer a more predictable work schedule and get our team home injury-free every night.” Waupaca Foundry purchased
its first Brokk machine in 2000 to increase its efficiency and safety and reduce injuries to employees. Te team started with a 1.6-ton Brokk 150 to remove the refractory lining in the 80-ft.-tall cupola, effectively minimiz- ing the use of pneumatic tools. “Before using remote-controlled
machines our team removed refrac- tory material by hand, using pneumatic hand tools, leading to increased physi- cal stress and risk of injury,” Heger said. “To overcome the physical demands, we needed something that was compact enough to maneuver around our facility, yet offered the power of handheld tools. Tat’s when we turned to Brokk.” Less than 5 ft. tall and 3 ft. wide,
the Brokk 150 can move through a standard doorway. Despite its compact size, the machine’s power removes the refractory material. And since it was remote-controlled, the Brokk 150 allows operators to stay away from the high temperatures inside the cupola, which minimizes the risk of heat exhaustion. In addition, the machines are electric-powered, resulting in no potentially harmful exhaust. Waupaca Foundry now uses five
electric-powered Brokk machines in three of its seven metalcasting plants. Te Brokk machines weigh 1-3 tons each and include a Brokk 150, 180, 250 as well as two Brokk 100s. Before using remote-controlled
equipment, cleaning the cupola spout required eight laborers using 30-lb. handheld pneumatic hammers, accord- ing to Waupaca Foundry. Te task took as long as 16 hours to complete. Using Brokk machines cut labor time nearly in half. Waupaca also uses a Brokk 250 to remove refractory from the pressure pour furnaces, which need cleaning every six months.
Waupaca Foundry uses five electric powered Brokk machines in three of its plants. The Brokk machines weigh 1 to 3 tons each and include a Brokk 150, 180, 250 as well as two Brokk 100s.
June 2016 MODERN CASTING | 47
Page 1 |
Page 2 |
Page 3 |
Page 4 |
Page 5 |
Page 6 |
Page 7 |
Page 8 |
Page 9 |
Page 10 |
Page 11 |
Page 12 |
Page 13 |
Page 14 |
Page 15 |
Page 16 |
Page 17 |
Page 18 |
Page 19 |
Page 20 |
Page 21 |
Page 22 |
Page 23 |
Page 24 |
Page 25 |
Page 26 |
Page 27 |
Page 28 |
Page 29 |
Page 30 |
Page 31 |
Page 32 |
Page 33 |
Page 34 |
Page 35 |
Page 36 |
Page 37 |
Page 38 |
Page 39 |
Page 40 |
Page 41 |
Page 42 |
Page 43 |
Page 44 |
Page 45 |
Page 46 |
Page 47 |
Page 48 |
Page 49 |
Page 50 |
Page 51 |
Page 52 |
Page 53 |
Page 54 |
Page 55 |
Page 56 |
Page 57 |
Page 58 |
Page 59 |
Page 60
